1986-1993 Volvo 240 Manual Transmission Replacement · Lower the transmission out of the car. In many instances, the transmission may not come free from the engine once the bolts

1986-1993 Volvo 240 Manual TransmissionReplacement

Remove or replace the manual transmission in a Volvo 240

Written By: Phillip Takahashi

1986-1993 Volvo 240 Manual Transmission Replacement Draft: 2019-04-05Guide ID: 7633 -

This document was generated on 2020-01-23 12:28:30 AM (MST).

© iFixit — CC BY-NC-SA www.iFixit.com Page 1 of 6

Step 1 — Manual Transmission

Lift the bottom of the shift boot to expose the shifting socket.

Use snap ring pliers to remove the circlip securing the shifter to its socket.




Step 2

Remove the set screw securing the shifter yoke pin. This assembly can be located on theunderside of the car, above the transmission and directly below the shift lever.

Grab the head of the shifter yoke pin with your hands or pliers and pull it out.

If the pin won't readily come free, try jiggling the shifter while you pull the pin.




Step 3

Remove the shift lever by pulling it straight up.

Remove the plastic bushing in the bottom of the shifter socket.

Step 4

Remove the 6 nuts and boltssecuring the drive shaft to the guiboand the back side of thetransmission.

Only four nuts and bolts arevisible and marked in the firstpicture. The others are hidden onthe other side of the drive shaft.

Take note of how the bolts, washersand guibo are positioned. They arerequired to go back in the sameway.




Step 5

Support the drive shaft with a jack, jack stand, or other prop so it does not fall and get damaged orinjure someone when the support is removed.

Remove the 4 bolts securing the drive shaft support.

Do not lose the washers on the 4 bolts or the spring and washer on the opposite side of thesupport.

Slowly lower the drive shaft and separate it from the transmission.

Remove the guibo and metal separator plate.

The separator may not come out with drive line and will be in the transmission.




To reassemble your device, follow these instructions in reverse order.

Step 6

Remove the bolts securing the transmission to the engine and to the starter.

Support the transmission so it doesn't fall when the final support is removed.Generally, a jack is recommended for this.

Remove the four bolts securing the transmission support to the chassis.

Lower the transmission out of the car.

In many instances, the transmission may not come free from the engine once the bolts areremoved. If this is the case, a pry bar is recommended to help separate the two.




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1986-1993 Volvo 240 Manual Transmission Replacement · Lower the transmission out of the car. In many instances, the transmission may not come free from the engine once the bolts